Electronic component and method for manufacturing the same

ABSTRACT

A laminate includes ceramic layers laminated to each other. Internal conductors are embedded in the laminate and include exposed portions that are exposed between the ceramic layers at a lower surface and an upper surface of the laminate. External electrodes are directly plated on the lower surface and the upper surface so as to cover the respective exposed portions. Regions of the lower surface at which the exposed portions are provided are arranged to protrude from the other regions of the lower surface, and regions of the upper surface at which the exposed portions are provided are arranged to protrude from the other regions of the upper surface.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an electronic component and a method for manufacturing the same, and more particularly relates to an electronic component including a laminate in which ceramic layers are laminated to each other and a method for manufacturing the same.

2. Description of the Related Art

As a related electronic component, for example, a multilayer electronic component disclosed in Japanese Unexamined Patent Application Publication No. 2008-47907 is known. The multilayer electronic component described above includes a plurality of dielectric layers, a plurality of internal electrodes, and terminals. The dielectric layers and the internal electrodes are alternately laminated to each other. The terminals are external electrodes provided on side surfaces of a laminate including the dielectric layers. In the multilayer electronic component described above, the internal electrodes are exposed at the side surfaces of the laminate, and the terminals are formed by plating regions at which the internal electrodes are exposed.

In an electronic component including external electrodes which are formed by plating, such as the multilayer electronic component described above, it is desirable to form the external electrodes in a short time.

SUMMARY OF THE INVENTION

Accordingly, preferred embodiments of the present invention provide an electronic component including external electrodes which can be formed in a short time and a method for manufacturing the same.

An electronic component according to a preferred embodiment of the present invention includes a laminate including ceramic layers laminated to each other; a first internal conductor and a second internal conductor which are embedded in the laminate and include a first exposed portion and a second exposed portion, respectively, exposed between the ceramic layers at a mounting surface of the laminate; and a first external electrode and a second external electrode directly disposed on the mounting surface so as to cover the first exposed portion and the second exposed portion, respectively, wherein regions of the mounting surface at which the first exposed portion and the second exposed portion are provided protrude from the other regions of the mounting surface.

According to another preferred embodiment of the present invention, a method for manufacturing the above electronic component includes the steps of preparing the laminate in which the first internal electrode and the second internal electrode are embedded; performing a polishing process on the laminate so that the mounting surface thereof is concavely curved between the region at which the first exposed portion is provided and the region at which the second exposed portion is provided; and forming the first external electrode and the second external electrode by direct plating so as to cover the first exposed portion and the second exposed portion, respectively.

According to preferred embodiments of the present invention, the external electrodes can be formed in a short time.

The above and other elements, features, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiments with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an appearance perspective view of an electronic component according to a preferred embodiment of the present invention.

FIG. 2 is an exploded perspective view of a laminate of the electronic component according to a preferred embodiment of the present invention.

FIG. 3 is a perspective view of the electronic component when viewed from above in a lamination direction according to a preferred embodiment of the present invention.

FIG. 4A is a view of an electronic component according to a preferred embodiment of the present invention mounted on a circuit board.

FIG. 4B is a view of an electronic component according to a comparative example mounted on a circuit board.

FIG. 5 is a perspective view of an electronic component according to a first modified preferred embodiment when viewed from above in a lamination direction.

FIG. 6 is a perspective view of an electronic component according to a second modified preferred embodiment when viewed from above in a lamination direction.

FIG. 7 is a perspective view of an electronic component according to a third modified preferred embodiment when viewed from above in a lamination direction.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, an electronic component according to preferred embodiments of the present invention and a method for manufacturing the same will be described with reference to the drawings.

First, the structure of an electronic component will be described with reference to the drawings. FIG. 1 is an appearance perspective view of an electronic component 10. FIG. 2 is an exploded perspective view of a laminate 12 of the electronic component 10. FIG. 3 is a perspective view of the electronic component 10 when viewed from above in a lamination direction. In this preferred embodiment, a lamination direction of the laminate 12 is defined as a y axis direction. When the laminate 12 is plan viewed in the y axis direction, a longer side direction of the laminate 12 is defined as an x axis direction. When the laminate 12 is plan viewed in the y axis direction, a shorter side direction of the laminate 12 is defined as a z axis direction.

As shown in FIGS. 1 and 2, the electronic component 10 is a chip capacitor which includes the laminate 12, external electrodes 14 (14 a and 14 b) and 15 (15 a and 15 b), and a capacitor C (not shown in FIG. 1). The laminate 12 preferably has a substantially rectangular parallelepiped shape. However, since chamfering is performed, the laminate 12 preferably includes substantially round-shaped corners and ridge lines. Hereinafter, in the laminate 12, a surface at a positive direction side in the y axis direction is called a side surface S1, and a surface at a negative direction side in the y axis direction is called a side surface S2. In addition, a surface at a negative direction side in the x axis direction is called an end surface S3, and a surface at a positive direction side in the x axis direction is called an end surface S4. Furthermore, a surface at a positive direction side in the z axis direction is called an upper surface S5, and a surface at a negative direction side in the z axis direction is called a lower surface S6.

As shown in FIG. 2, the laminate 12 is preferably formed by laminating a plurality of ceramic layers 16. The ceramic layers 16 preferably each have a substantially rectangular shape and are each formed from a dielectric ceramic.

As an example of the dielectric ceramic, for example, BaTiO₃, CaTiO₃, SrTiO₃, or CaZrO₃ may be used. In addition, at least one of the above materials may be used as a primary component, and at least one of a Mn compound, a Fe compound, a Cr compound, a Co compound, and a Ni compound may be used as an accessory component. The thickness of the ceramic layer 16 is preferably set in a range of about 0.5 μm to about 10 μm, for example. Hereinafter, a primary surface of the ceramic layer 16 at the positive direction side in the y axis direction is called a front surface, and a primary surface of the ceramic layer 16 at the negative direction side in the y axis direction is called a rear surface.

As described above, the side surface S1 of the laminate 12 is defined by the front surface of a ceramic layer 16 provided at the most positive direction side in the y axis direction.

The side surface S2 of the laminate 12 is defined by the rear surface of a ceramic layer 16 provided at the most negative direction side in the y axis direction. In addition, the end surface S3 is defined by the shorter sides of the ceramic layers 16 at the negative direction side in the x axis direction. The end surface S4 is defined by the shorter sides of the ceramic layers 16 at the positive direction side in the x axis direction. The upper surface S5 is defined by the longer sides of the ceramic layers 16 at the positive direction side in the z axis direction. The lower surface S6 is defined by the longer sides of the ceramic layers 16 at the negative direction side in the z axis direction.

As shown in FIG. 2, the capacitor C is preferably defined by capacitor conductors (internal conductors) 18 (18 a and 18 b) embedded in the laminate 12. It is preferable that the capacitor conductors 18 be formed, for example, of a conductive material, such as Ni, Cu, Ag, Pd, a Ag—Pd alloy, or Au, and have a thickness in a range of about 0.3 μm to about 2.0 μm, for example.

The capacitor conductor 18 a is provided on the surface of one ceramic layer 16 and has a capacity portion 20 a and lead portions 22 a and 24 a. The capacity portion 20 a has a substantially rectangular shape and is not in contact with an outer edge of the ceramic layer 16. The lead portion 22 a protrudes toward the negative direction side in the z axis direction from the vicinity of an end portion at the negative direction side in the x axis direction of a longer side at the negative direction side in the z axis direction of the capacity portion 20 a. Accordingly, the lead portion 22 a is extended to the longer side of the ceramic layer 16 at the negative direction side in the z axis direction. At a front end portion at the negative direction side in the z direction, the lead portion 22 a has an exposed portion 26 a that is exposed between adjacent two ceramic layers 16 at the lower surface S6 of the laminate 12. The lead portion 24 a protrudes toward the positive direction side in the z axis direction from the vicinity of an end portion at the negative direction side in the x axis direction of a longer side at the positive direction side in the z axis direction of the capacity portion 20 a. Accordingly, the lead portion 24 a is extended to the longer side of the ceramic layer 16 at the positive direction side in the z axis direction. At a front end portion at the positive direction side in the z direction, the lead portion 24 a includes an exposed portion 28 a exposed between the adjacent two ceramic layers 16 at the upper surface S5 of the laminate 12.

The capacitor conductor 18 b is provided on the surface of one ceramic layer 16 and includes a capacity portion 20 b and lead portions 22 b and 24 b. The capacity portion 20 b has a substantially rectangular shape and is not in contact with an outer edge of the ceramic layer 16. In addition, the capacity portion 20 b faces the capacity portion 20 a with the ceramic layer interposed therebetween. Accordingly, the capacity is generated between the capacity portions 20 a and 20 b. The lead portion 22 b protrudes toward the negative direction side in the z axis direction from the vicinity of an end portion at the positive direction side in the x axis direction of a longer side at the negative direction side in the z axis direction of the capacity portion 20 b. Accordingly, the lead portion 22 b is extended to the longer side of the ceramic layer 16 at the negative direction side in the z axis direction. The lead portion 22 b is located at the positive direction side in the x axis direction than the lead portion 22 a. At a front end portion at the negative direction side in the z direction, the lead portion 22 b includes an exposed portion 26 b exposed between adjacent two ceramic layers 16 at the lower surface S6 of the laminate 12. The lead portion 24 b protrudes toward the positive direction side in the z axis direction from the vicinity of an end portion at the positive direction side in the x axis direction of a longer side at the positive direction side in the z axis direction of the capacity portion 20 b. Accordingly, the lead portion 24 b is extended to the longer side of the ceramic layer 16 at the positive direction side in the z axis direction. The lead portion 24 b is located at the positive direction side in the x axis direction than the lead portion 24 a. At a front end portion at the positive direction side in the z axis direction, the lead portion 24 b has an exposed portion 28 b exposed between the adjacent two ceramic layers 16 at the upper surface S5 of the laminate 12.

The capacitor conductors 18 a and 18 b are preferably arranged on a plurality of the ceramic layers 16 so as to be alternately disposed in the y axis direction. Accordingly, the capacitor C is located at a region at which the capacitor conductor 18 a faces the capacitor conductor 18 b with the ceramic layer 16 interposed therebetween. In addition, a region in which the ceramic layers 16 provided with the capacitor conductors 18 are laminated is called an inner layer region. In addition, at a positive direction side of the inner layer region in the y axis direction, ceramic layers 16 each provided with no capacitor conductor 18 are laminated. As in the case described above, at a negative direction side of the inner layer region in the y axis direction, ceramic layers 16 each provided with no capacitor conductor 18 are laminated. Hereinafter, the two regions in which the ceramic layers 16 each provided with no capacitor conductors 18 are laminated are each called an outer layer region.

The external electrodes 14 a and 14 b preferably are disposed directly on the lower surface S6 of the laminate 12 so as to cover the exposed portions 26 a and 26 b, respectively. The external electrode 14 a is located at the negative direction side in the x axis direction than the external electrode 14 b. The external electrodes 15 a and 15 b are disposed directly on the upper surface S5 of the laminate 12 so as to cover the exposed portions 28 a and 28 b, respectively. The external electrode 15 a is located at the negative direction side in the x axis direction than the external electrode 15 b. Since the external electrodes 14 and 15 are provided as described above, the capacitor C is connected between the external electrodes 14 a and 15 a and the external electrodes 14 b and 15 b. As a material for the external electrodes 14 and 15, for example, Cu may preferably be used.

The electronic component 10 has a unique structure which enables the external electrodes 14 and 15 to be formed in a short time. Hereinafter, this structure will be described in detail.

In the electronic component 10, as shown in FIG. 3, regions of the lower surface S6 at which the exposed portions 26 a and 26 b are provided protrude toward the negative direction side in the z axis direction from the other regions of the lower surface S6. An area including the exposed portions 26 a and 26 b is an area including the exposed portions 26 a and 26 b and portions of ceramic layers 16 provided therebetween. In other words, the lower surface S6 is concavely curved toward the positive direction side in the z axis direction between the region at which the exposed portion 26 a is provided and the region at which the exposed portion 26 b is provided. Furthermore, in this preferred embodiment, the lower surface S6 has a continuous curved surface between the region at which the exposed portion 26 a is provided and the region at which the exposed portion 26 b is provided. As described above, since the regions of the lower surface S6 at which the exposed portions 26 a and 26 b are provided protrude and the other regions of the lower surface S6 sink, as shown by an enlarged view of FIG. 3, the exposed portions 26 a and 26 b each have, besides a portion P1 parallel to the x-axis, portions P2 and P3 inclined to the x axis.

In addition, as shown in FIG. 3, the regions of the upper surface S5 at which the exposed portions 28 a and 28 b are provided protrude toward the positive direction side in the z axis direction from the other regions of the upper surface S5. However, since the structures of the exposed portions 28 a and 28 b and the upper surface S5 are the same as those of the exposed portions 26 a and 26 b and the lower surface S6, a further description will be omitted.

The electronic component 10 thus formed is mounted on a circuit board for use. Hereinafter, mounting of the electronic component 10 will be described with reference to the drawings. FIG. 4A is a view of the electronic component 10 according to this preferred embodiment mounted on a circuit board 200.

The circuit board 200 preferably is a printed-circuit board or the like and includes, as shown in FIG. 4A, lands 202 (202 a and 202 b) to mount the electronic component 10. When the electronic component 10 is mounted on the circuit board 200, the lower surface S6 is used as a mounting surface and is arranged to face a primary surface of the circuit board 200. In addition, the external electrodes 14 a and 14 b are arranged to face the lands 202 a and 202 b, respectively, and are then fixed thereon by solder. Accordingly, the electronic component 10 is mounted on the circuit board 200. In addition, in the electronic component 10, the upper surface S5 may be used as the mounting surface instead.

Next, a method for manufacturing the electronic component 10 according to a preferred embodiment of the present invention will be described. The method will be described with reference to FIGS. 1 to 3.

After BaTiO₃, CaTiO₃, SrTiO₃ or CaZrO₃ used as a primary component and a Mn compound, a Fe compound, a Cr compound, a Co compound, or a Ni compound used as an accessory component are weighed at a predetermined ratio and are then charged in a ball mill, wet mixing is performed. An obtained mixture is dried and is then pulverized, and an obtained powder is then calcined. After a calcined powder thus obtained is wet-pulverized, drying and pulverizing are sequentially performed, so that a dielectric ceramic powder is obtained.

To this dielectric ceramic powder, an organic binder and an organic solvent are added, and mixing is then performed using a ball mill. After an obtained ceramic slurry is formed into sheets on a carrier sheet by a doctor blade method, drying is performed so as to form ceramic green sheets which are to be formed into the ceramic layers 16. The thickness of each ceramic green sheet which is to be formed into the ceramic layer 16 is preferably in a range of about 0.5 μm to about 10 μm, for example.

Next, the capacitor conductors 18 a and 18 b are formed on the ceramic green sheets which are to be formed into the ceramic layers 16 by applying a paste containing a conductive material using a method, such as a screen printing or a photolithographic method. As the paste containing a conductive material, for example, a paste formed by adding an organic binder and an organic solvent to a metal powder may be used.

Next, the ceramic green sheets which are to be formed into the ceramic layers 16 are laminated, so that a green mother laminate is obtained. Subsequently, pressure bonding is performed on the green mother laminate by a hydrostatic pressure press.

Next, the green mother laminate is cut into a plurality of green laminates 12 each having a predetermined size. Next, the green laminate 12 is fired. As a firing temperature, for example, a temperature in a range of approximately 900° C. to 1,300° C. is preferable. By the steps described above, a fired laminate 12 in which the capacitor conductors 18 are embedded is prepared.

Next, a polishing process, such as a barrel polishing process, is performed on the surface of the laminate 12. More particularly, a barrel polishing process is performed so that the lower surface S6 is concavely curved between the region at which the exposed portion 26 a is provided and the region at which the exposed portion 26 b is provided and so that the upper surface S5 is concavely curved between the region at which the exposed portion 28 a is provided and the region at which the exposed portion 28 b is provided. In order to process the upper surface S5 and the lower surface S6 as described above, for example, a barrel polishing process may be performed for a relatively long time. The laminate 12 has a high brittleness as compared to that of the capacitor conductor 18. Hence, a region of the lower surface S6 between the region at which the exposed portion 26 a is provided and the region at which the exposed portion 26 b is provided and a region of the upper surface S5 between the portion at which the exposed portion 28 a is provided and the region at which the exposed portion 28 b is provided are more polished as compared to the regions of the upper surface S5 and the lower surface S6 at which the exposed portions 26 a, 26 b, 28 a, and 28 b are provided. As a result, the regions of the upper surface S5 and the lower surface S6 at which the exposed portions 26 a, 26 b, 28 a, and 28 b are provided protrude from the other regions, a continuous curved surface is provided between the region at which the exposed portion 26 a is provided and the region at which the exposed portion 26 b is provided, and in a manner similar to that described above, a continuous curved surface is formed between the region at which the exposed portion 28 a is provided and the region at which the exposed portion 28 b is provided.

By the barrel polishing process as described above, the exposed portions 26 a, 26 b, 28 a, and 28 b are more widely exposed from the upper surface S5 and the lower surface S6 as compared to those before the barrel polishing process is performed.

Next, the external electrodes 14 and 15 are formed from Cu by a plating method. In particular, the laminate 12 is charged in a barrel containing conductive media. Subsequently, the barrel is immersed in a plating solution and is rotated for a predetermined time. Accordingly, the conductive media come into contact with the exposed portions 26 a, 26 b, 28 a, and 28 b, so that an electrical power is supplied. As a result, Cu is deposited on the exposed portions 26 a, 26 b, 28 a, and 28 b, so that the external electrodes 14 and 15 are formed. By the steps described above, the electronic component 10 is formed.

According to the electronic component 10 and the method for manufacturing the same, the external electrodes 14 and 15 can be formed in a short time. In more particular, in a common electronic component, the side surface of a laminate thereof is flat. Hence, only the portion P1 parallel to the x axis of FIG. 3 is exposed from the side surface of the laminate, and the portions P2 and P3 inclined to the x axis are not exposed from the side surface of the laminate.

On the other hand, in the electronic component 10, as shown in FIG. 3, the portion P1 parallel to the x axis and the portions P2 and P3 inclined thereto are exposed from each of the upper surface S5 and the lower surface S6 of the laminate 12. Therefore, in the electronic component 10, the area of the capacitor conductor 18 exposed from the laminate 12 is larger than that of a common electronic component by the area of the portions P2 and P3 inclined to the x axis. Accordingly, the conductive media can easily come into contact with the capacitor conductor 18 as compared to the case of a common electronic component. As a result, according to the electronic component 10 and the method for manufacturing the same, the formation of the external electrodes 14 and 15 is promoted and can be performed in a short time.

In this preferred embodiment, in the electronic component 10, the exposed portions 26 a and 26 b and the exposed portions 28 a and 28 b preferably are exposed only from the lower surface S6 and the upper surface S5, respectively, and preferably are not exposed from the other surfaces. Hence, the probability of the conductive media to come into contact with the exposed portions 26 a, 26 b, 28 a, and 28 b of the electronic component 10 is relatively low. Accordingly, when the regions of the upper surface S5 and the lower surface S6 at which the exposed portions 26 a, 26 b, 28 a, and 28 b are provided are allowed to protrude from the other regions of the surfaces S5 and S6 so as to increase the probability of the conductive media to come into contact with the exposed portions 26 a, 26 b, 28 a, and 28 b, in the electronic component 10, a significant advantage in that the external electrodes 14 and 15 can be formed in a short time can be achieved.

In addition, when the electronic component 10 is mounted on the circuit board 200, a short circuit generated between the external electrodes 14 a and 14 b can be prevented. Hereinafter, the reason for this will be described with reference to FIGS. 4A and 4B. FIG. 4B is a view showing an electronic component 110 according to a comparative example mounted on the circuit board 200. The electronic component 110 according to the comparative example has a flat upper surface S5 and a flat lower surface S6, and this flat surface is different from that of the electronic component 10.

As shown in FIG. 4B, excessive solders 204 a and 204 b are generated when the electronic component 110 is mounted on the circuit board 200. The excessive solders 204 a and 204 b are extended between the lower surface S6 used as a mounting surface and the primary surface of the circuit substrate 200 in the x axis direction. In addition, when the amount of the excessive solders 204 a and 204 b is large, the excessive solders 204 a and 204 b come into contact with each other. As a result, a short circuit occurs between external electrodes 114 a and 114 b.

On the other hand, in the electronic component 10, the lower surface S6 functioning as a mounting surface sinks toward the positive direction side in the z axis direction. Therefore, a space between the lower surface S6 of the electronic component and the primary surface of the circuit board 200 is larger than that between the lower surface S6 of the electronic component 110 and the primary surface of the circuit board 200. Hence, the excessive solders 204 a and 204 b are prevented from extending in the x axis direction so as to come into contact with each other. As a result, in the electronic component 10, a short circuit generated between the external electrodes 14 a and 14 b can be suppressed.

In some cases, the electronic component 10 may be mounted in a circuit board in an embedded state. In particular, a circuit board having a recess portion is prepared. Next, the electronic component 10 is mounted in the recess portion. In this case, a resin adhesive for fixing the electronic component 10 is filled in this recess portion. Next, insulating layers are laminated so as to close the recess portion, thereby forming the circuit board. In this case, the lower surface S6 of the electronic component 10 sinks toward the positive direction side in the z axis direction. Hence, when the electronic component 10 is embedded in the circuit board as described above, the adhesive is likely to enter the space between the lower surface S6 of the electronic component 10 and a mounting surface of the circuit board. As a result, the electronic component 10 is tightly fixed to the circuit board.

The present inventors carried out the following experiments in order to more clarify the advantages of the electronic component 10 according to a preferred embodiment of the present invention. In particular, six types of electronic components having the following conditions were formed. 10 pieces of electronic components were formed respectively for the first to fifth example and comparative example.

Size: 1.0 mm×0.5 mm×0.5 mm Number of ceramic layers: 475 layers Number of ceramic layers in an inner layer region: 445 layers Number of ceramic layers in each outer layer region: 15 layers Material for a ceramic layer: Barium titanate-based dielectric ceramic Thickness of each ceramic layer: 0.7 μm Material for a capacitor conductor: A metal containing Ni as a primary component. Rated voltage: 4.0 V Electrostatic capacitance: 10 μF

One example of barrel polishing process conditions for forming the six types of electronic components is shown below.

Barrel apparatus: Wet barrel apparatus Media: Zirconia ball (1.0 mm in diameter)

Pod: 340 cc

Number of revolutions: 250 rpm Process time: 10 to 300 minutes

One example of conditions of a strike plating method for forming the six types of electronic components is shown below.

Thickness: 5 μm

Plating solution: “Pyrobright process (Pyrobright PY-61 bath)” manufactured by Uyemura & CO., LTD. Bath temperature: 55° C. pH: 8.6 Barrel: Horizontal rotation barrel Number of revolutions: 60 rpm Diameter of conductive media: 0.4 mm Current density: 0.1 A/dm2 Time: 300 minutes

Among the six types of electronic components, a ratio X (=D/L×100(%)) of a protrusion amount D to a length L shown in FIG. 3 was different from each other as shown in a first to a fifth example and a comparative example. The protrusion amount D was obtained by measuring a surface shape of the upper surface S5 and that of the lower surface S6 using a laser displacement gauge (KS-1100: manufactured by KEYENCE Corporation). In addition, the length L was measured by a slide caliper. The ratio X was an average of values of 10 pieces in each of the first to fifth example and comparative example.

First example: 1.7% Second example: 5.3% Third example: 7.9% Fourth example: 11.5% Fifth example: 17.2%

Comparative Example: 0%

In addition, in order to change the ratio X, a barrel polishing process time was changed. In particular, the times were set to 10, 30, 90, 180, 300, and 0 minutes in the first example, the second example, the third example, the fourth example, the fifth example, the comparative example, respectively. Since the barrel polishing process conditions were the same as those described above, a description thereof is omitted. In addition, since the plating conditions for forming the external electrodes 14 and 15 were also the same as those described above, a description thereof is also omitted.

The thicknesses of the external electrodes 14 and 15 formed in each of the first to the fifth examples and the comparative example were measured. By using XRF (SFT-9450: manufactured by SII Nano Technology Inc.), the thickness was obtained in such a way that x-ray intensity was measured and was then converted into the thickness using a detection line method. The thicknesses of the external electrodes 14 and 15 were an average of values of 10 pieces in each of the first to fifth example and comparative example. Table 1 is a table showing the experimental results.

TABLE 1 Film Thickness (μm) First example 4.8 Second example 5.0 Third example 5.3 Fourth example 5.6 Fifth example 5.7 Comparative example 4.7

As shown in Table 1, it is found that as the ratio X is increased, the thickness is increased. That is, it is found that the formation rate of the external electrodes 14 and 15 is increased as the ratio X is increased. Accordingly, it is found that when the regions of the upper surface S5 and the lower surface S6 at which the exposed portions 26 a, 26 b, 28 a, and 28 b are provided are allowed to protrude from the other regions, the external electrodes 14 and 15 can be formed in a short time.

FIG. 5 is a perspective view of an electronic component 10′ according to a first modified preferred embodiment when viewed from above in a lamination direction. As the electronic component 10′ shown in FIG. 5, the external electrodes 15 a and 15 b and the lead portions 24 a and 24 b may not be provided.

FIG. 6 is a perspective view of an electronic component 10 a according to a second modified preferred embodiment when viewed from above in a lamination direction. The electronic component 10 a shown in FIG. 6 has the capacitor conductors 18 a and 18 b and lead portion 56 a and 56 b. In addition, instead of using the external electrodes 14 a, 14 b, 15 a, and 15 b, external electrodes 54 a and 54 b are provided.

The lead portions 56 a are extended to the shorter side of the ceramic layer 16 at the negative direction side in the x axis direction. Accordingly, each lead portion 56 a has an exposed portion 58 a exposed between adjacent two ceramic layers 16 at the end surface S3. The exposed portion 58 a is connected to the exposed portions 26 a and 28 a.

The lead portions 56 b are extended to the shorter side of the ceramic layer 16 at the positive direction side in the x axial direction. Accordingly, each lead portion 56 b has an exposed portion 58 b exposed between adjacent two ceramic layers 16 at the end surface S4. The exposed portion 58 b is connected to the exposed portions 26 b and 28 b.

The external electrode 54 a is provided on the end surface S3, the upper surface S5, and the lower surface S6 so as to cover the exposed portions 26 a, 28 a, and 58 a. As shown in FIG. 6, the external electrode 54 a plan viewed from the positive direction side in the y axial direction has a substantially U shape.

The external electrode 54 b is provided on the end surface S4, the upper surface S5, and the lower surface S6 so as to cover the exposed portions 26 b, 28 b, and 58 b. As shown in FIG. 6, the external electrode 54 b plan viewed from the positive direction side in the y axial direction has a substantially U shape.

According to the electronic component 10 a described above, as in the electronic component 10 described above, the external electrodes 54 can also be formed in a short time.

FIG. 7 is a plan view of an electronic component 10 b according to a third modified preferred embodiment when viewed from above in a laminating direction. In the electronic component 10 b shown in FIG. 7, the lead portion 56 a is not connected to the lead portions 22 a and 24 a. As in the case described above, the lead portion 56 b is not connected to the lead portions 22 b and 24 b. In addition, the electronic component 10 b further includes external electrodes 60 a and 60 b.

The lead portions 56 a are extended to the shorter side of the ceramic layer 16 at the negative direction side in the x axial direction. Accordingly, each lead portion 56 a has the exposed portion 58 a exposed between adjacent two ceramic layers 16 at the end surface S3. However, the exposed portion 58 a is not connected to the exposed portions 26 a and 28 a. That is, the capacitor conductor 18 a is not provided at the corner of the ceramic layer 16.

The lead portions 56 b are extended to the shorter side of the ceramic layer 16 at the positive direction side in the x axial direction. Accordingly, each lead portion 56 b includes the exposed portion 58 b exposed between adjacent two ceramic layers 16 at the end surface S4. However, the exposed portion 58 b is not connected to the exposed portions 26 b and 28 b. That is, the capacitor conductor 18 b is not provided at the corner of the ceramic layer 16.

The region of the end surface S3 at which the exposed portion 58 a is provided protrudes toward the negative direction side in the x axis direction from the other regions of the end surface S3. As in the case described above, the region of the end surface S4 at which the exposed portion 58 b is provided protrudes toward the positive direction side in the x axis direction from the other regions of the end surface S4.

The external electrode 60 a is arranged on the end surface S3 so as to cover the exposed portion 58 a. The external electrode 60 b is provided on the end surface S4 so as to cover the exposed portion 58 b.

According to the above electronic component 10 b, as is the case of the electronic component 10, the external electrodes 14, 15 and 60 can also be formed in a short time.

The electronic component 10 according to the present invention is not limited to those described in the above preferred embodiments and may be modified within the scope of the present invention.

In addition, in the electronic components 10, 10′, 10 a, and 10 b, the circuit element embedded in the laminate 12 is not limited to the capacitor C. Hence, as the circuit element, a piezoelectric component, a resistor, a coil, a thermistor, or the like may be used, for example. When the circuit element is a piezoelectric component, for example, a piezoelectric ceramic, such as a PZT-based ceramic, may be used as a material for the ceramic layer 16. In addition, when the circuit element is a thermistor, for example, a semiconductor ceramic, such as a spinel-based ceramic, may be used as a material for the ceramic layer 16. Furthermore, when the circuit element is a coil, for example, a magnetic ceramic may be used as a material for the ceramic layer 16.

In addition, in addition to the plating method described above, the external electrodes 14, 15, 54 a, 54 b, 60 a, and 60 b may be formed by performing a plating method twice, for example. In particular, after an underlayer plating film is formed by a first plating method, an upper layer plating film may be then formed on the underlayer plating film by a second plating method. A material for the underlayer plating film and the upper layer plating film preferably is a metal selected from the group consisting of Cu, Ni, Sn, Pb, Au, Ag, Pd, Bi, and Zn or an alloy formed of at least two thereof. When Ni is used as a material for the capacitor conductor 18, Cu, which has good compatibility with Ni, is preferably used as the material for the underlayer plating film. In addition, the upper layer plating film may be formed to have a two-layered structure which includes a first upper layer plating film and a second upper layer plating film. As a material for the first upper layer plating film in contact with the underlayer plating film, Ni, which is not likely to be eroded by a solder, is preferably used. In addition, as a material for the second upper layer plating film exposed to the outside, Sn or Au, which is excellent in solder wettability, is preferably used. The thicknesses of the underlayer plating film, the first upper layer plating film, and the second upper layer plating film are each preferably in a range of about 1 μm to about 15 μm, for example.

As described above, preferred embodiments of the present invention are effectively applied to an electronic component and a method for manufacturing the same and are particularly superior since the external electrodes can be formed in a short time.

While preferred embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims. 

1. An electronic component comprising: a laminate including ceramic layers laminated to each other; a first internal conductor and a second internal conductor which are embedded in the laminate and which include a first exposed portion and a second exposed portion, respectively, exposed between the ceramic layers at a mounting surface of the laminate; and a first external electrode and a second external electrode directly plated on the mounting surface so as to cover the first exposed portion and the second exposed portion, respectively; wherein regions of the mounting surface at which the first exposed portion and the second exposed portion are provided protrude from other regions of the mounting surface.
 2. The electronic component according to claim 1, wherein a region at which the first internal conductor and the second internal conductor face each other with at least one of the ceramic layers interposed therebetween defines a capacitor.
 3. The electronic component according to claim 1, wherein the mounting surface is concavely curved between the region at which the first exposed portion is provided and the region at which the second exposed portion is provided.
 4. The electronic component according to claim 3, wherein the mounting surface is a continuous curved surface between the region at which the first exposed portion is provided and the region at which the second exposed portion is provided.
 5. A method for manufacturing the electronic component according to claim 1 comprising the steps of: preparing the laminate in which the first internal electrode and the second internal electrode are embedded; performing a polishing process on the laminate so that the mounting surface thereof is concavely curved between the region at which the first exposed portion is provided and the region at which the second exposed portion is provided; and forming the first external electrode and the second external electrode by direct plating so as to cover the first exposed portion and the second exposed portion, respectively. 